Modular thermal isolation barrier for data processing equipment structure

ABSTRACT

A data processing equipment structure includes a plurality of vertical and horizontal frame components, which, together, define an equipment structure frame, and a plurality of panels disposed relative to the equipment structure frame to define a periphery. At least one of the plurality of vertical and horizontal frame components is an extruded strut having a generally uniform cross-section. The extruded strut includes an outwardly-facing channel extending along each of a pair of opposing sides of the extruded strut, at least one of which includes a set of evenly-spaced ridges, extending along each of two sides of the channel, for accommodating a threaded fastener. The extruded strut further includes one or more ledges, each having a depth sufficient to accommodate a thickness of one of the plurality of panels.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a U.S. continuation patent application of,and claims priority under 35 U.S.C. § 120 to, U.S. nonprovisional patentapplication Ser. No. 16/807,836, filed Mar. 3, 2020, which '836application published as U.S. Patent Application Publication No. US2020/0205317 A1 on Jun. 25, 2020, which '836 application and theapplication publication thereof are each expressly incorporated hereinby reference in their entirety, and which '836 application is a U.S.continuation patent application of, and claims priority under 35 U.S.C.§ 120 to, U.S. nonprovisional patent application Ser. No. 16/519,901,filed Jul. 23, 2019, which '901 application published as U.S. PatentApplication Publication No. US 2019/0350108 A1 on Nov. 14, 2019 andissued as U.S. Pat. No. 10,595,442 on Mar. 17, 2020, which '901application, the application publication thereof, and the patent issuingtherefrom are each expressly incorporated herein by reference in theirentirety, and which '901 application is a U.S. continuation patentapplication of, and claims priority under 35 U.S.C. § 120 to, U.S.nonprovisional patent application Ser. No. 15/730,881, filed Oct. 12,2017, which '881 application published as U.S. Patent ApplicationPublication No. US 2018/0035570 A1 on Feb. 1, 2018 and issued as U.S.Pat. No. 10,375,861 on Aug. 6, 2019, which '881 application, theapplication publication thereof, and the patent issuing therefrom areeach expressly incorporated herein by reference in their entirety, andwhich '881 application is a U.S. continuation patent application of, andclaims priority under 35 U.S.C. § 120 to, U.S. nonprovisional patentapplication Ser. No. 15/424,804, filed Feb. 4, 2017, which '804application published as U.S. Patent Application Publication No. US2017/0150652 A1 on May 25, 2017 and issued as U.S. Pat. No. 9,795,060 onOct. 17, 2017, which '804 application, the application publicationthereof, and the patent issuing therefrom are each expresslyincorporated herein by reference in their entirety, and which '804application is a U.S. continuation patent application of, and claimspriority under 35 U.S.C. §120 to, U.S. nonprovisional patent applicationSer. No. 14/866,913, filed Sep. 26, 2015, which '913 applicationpublished as U.S. Patent Application Publication No. US 2016/0088773 A1on Mar. 24, 2016 and issued as U.S. Pat. No. 9,572,286 on Feb. 14, 2017,which '913 application, the application publication thereof, and thepatent issuing therefrom are each expressly incorporated herein byreference in their entirety, and which '913 application is a U.S.continuation patent application of, and claims priority under 35 U.S.C.§ 120 to, U.S. nonprovisional patent application Ser. No. 14/154,016,filed Jan. 13, 2014 and now abandoned, which '016 application publishedas U.S. Patent Application Publication No. US 2014/0196394 A1 on Jul.17, 2014, which '016 application and the application publication thereofare each expressly incorporated herein by reference in their entirety,and which '016 application is a U.S. nonprovisional patent applicationof, and claims priority under 35 U.S.C. § 119(e) to, each of thefollowing U.S. provisional patent applications:

-   -   (a) U.S. provisional patent application Ser. No. 61/751,260,        filed Jan. 11, 2013 and entitled, “MODULAR THERMAL ISOLATION        BARRIER FOR DATA PROCESSING EQUIPMENT STRUCTURES,” which '260        application is expressly incorporated herein by reference in its        entirety, and a copy of which is attached hereto as Appendix A,        which appendix is likewise expressly incorporated herein by        reference in its entirety; and    -   (b) U.S. provisional patent application Ser. No. 61/751,254,        filed Jan. 11, 2013 and entitled, “DATA PROCESSING EQUIPMENT        STRUCTURE,” which '254 application is expressly incorporated        herein by reference in its entirety, and a copy of which is        attached hereto as Appendix B, which appendix is likewise        expressly incorporated herein by reference in its entirety.

COPYRIGHT STATEMENT

All of the material in this patent document is subject to copyrightprotection under the copyright laws of the United States and othercountries. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in official governmental records but, otherwise, all othercopyright rights whatsoever are reserved.

BACKGROUND OF THE PRESENT INVENTION Field of the Present Invention

The present invention relates generally to structures and methods ofthermal management in a data center, and in particular, to housing dataprocessing equipment, and, in particular, to data processing equipmentstructures that can be structurally altered to seal around additionalopenings or obstruction to provide enhanced airflow solutions.

Background

Racks, frames and enclosures for mounting and storing computer and otherelectronic components or equipment have been well known for many years.Racks and frames are typically simple rectangular frameworks on whichelectronic components may be mounted, or on which other mountingmembers, such as shelves or brackets, may be mounted which in turn maysupport the electronic components. Enclosures are typically frames onwhich panels or doors, or both, are hung to provide aestheticimprovement, to protect the components from external influences, toprovide security for the components stored inside, or for other reasons.

Racks, frames and enclosures have been built in many different sizes andwith many different proportions in order to best accommodate thecomponents which they are designed to support and store. Componentsstored in these enclosures may include audio and video equipment and thelike, but quite frequently include computer equipment and relatedperipheral devices. These components typically include housingsenclosing internal operative elements.

As is also well known, the electronic equipment mounted in thesestructures tend to generate large amounts of thermal energy that needsto be exhausted away from the equipment effectively in order to maintainthe equipment in proper operating order or to prevent damage thereto.The problem can be especially significant when the components areenclosed in enclosures, because thermal energy generated thereby canconcentrate within the equipment enclosure and cause the components tooverheat and shut down. As equipment becomes more densely packed withelectronics, the quantities of thermal energy have continued to increasein recent years, and thermal energy management has become a significantissue confronting today's rack, frame and enclosure manufacturers, themanufacturers of the electronic equipment, and the users of suchequipment.

Typically, multiple racks, frames, enclosures, and the like (sometimescollectively referred to hereinafter as “enclosures”) are housedtogether in a data center room. Because of the overheating problem, andparticularly with multiple enclosures being placed in a single room,thermal management of the data center room is very important. A goal ofdata center thermal management is to maximize the performance, uptimeand life expectancy of the active components being housed in the room.Toward this end, data center rooms are often arranged so as to increaseefficiency and optimize performance.

One common way of organizing a data center room to meet these objectivesinvolves arranging individual enclosures in rows, with the air intake ofeach enclosure facing toward one side of the row and the heated airexhaust of each enclosure facing toward the other side of the row. Rowsof enclosures are arranged in back-to-back relationship so thatenclosures of two separate rows exhaust heated air into a common “hot”aisle between the rows. Heated exhaust air from the hot aisle is thendrawn into a cooling unit—often arranged as an in-line unit within therow of enclosures. The cooled air is then deposited back into theambient space of the data center room to be re-used in the coolingprocess.

In such an arrangement, however, several drawbacks are known to exist.For instance, the establishment of a hot aisle between rows eliminatesthe possibility of having dedicated cooling units to manage the coolingprocess for each row individually. Additionally, under existing hotaisle methodology, the entire space of the data center room must be keptcool in order to provide a ready supply of cooled air available to theenclosure intakes. Due to its typically large volume, the data centerroom is generally incapable of being adequately pressurized.

Accordingly, a need exists for improvement in the arrangement ofequipment enclosures within a data center room so as to further enhanceefficiency and performance. This, and other needs, is addressed by oneor more aspects of the present invention.

SUMMARY OF THE PRESENT INVENTION

Broadly defined, the present invention according to a first aspect is adata processing equipment structure comprising a plurality of struts andpanels, which, together, define an enclosed space.

Broadly defined, the present invention according to another aspect is adata processing equipment structure substantially as shown anddescribed.

Broadly defined, the present invention according to another aspect is amodular thermal isolation barrier for data processing equipmentstructures as shown and described.

Broadly defined, the present invention according to another aspect is amodular thermal isolation barrier, as shown and described.

Broadly defined, the present invention according to another aspect is anedge seal for a modular thermal isolation barrier, as shown anddescribed.

Broadly defined, the present invention according to another aspect is amodular thermal isolation barrier, including: a panel; and an edge sealarranged along an edge of the panel.

In a feature of this aspect, the modular thermal isolation barrierfurther includes a rigid support structure coupled along the length ofthe edge seal.

Broadly defined, the present invention according to another aspect is adata processing equipment structure comprising a plurality of rigidsupport structures, at least some of the rigid support structurescoupled to edge seals that are arranged along the respective edges ofpanels that define an enclosed space.

Broadly defined, the present invention according to another aspect is anextruded edge seal for a modular thermal isolation barrier, including: amulti-channel base portion; and a bulb seal portion.

In a feature of this aspect, the base portion and bulb seal portion areco-extruded.

In another feature of this aspect, the edge seal further includes panelretention fingers disposed within a channel of the multi-channel baseportion.

Broadly defined, the present invention according to another aspect is amodular thermal isolation barrier for use in sealing gaps in a dataprocessing equipment structure. The modular thermal isolation barrierincludes an extruded edge seal and a panel. The extruded edge seal has aseal portion and a base portion with one or more channels. An edge ofthe panel is disposed within one of the one or more channels of the baseportion of the edge seal such that the edge seal is seated against theedge of the panel with the seal portion in position to abut, andestablish a seal with, an adjacent structure.

In a feature of this aspect, the seal portion may include a bulb-shapedseal for abutting, and establishing a seal with, the adjacent structure.

In other features of this aspect, the bulb-shaped seal may be bifurcatedat a distal end; the bulb-shaped seal may include convex and concaveportions at a distal end; and/or the bulb-shaped seal may include one ormore protrusions at a distal end.

In another feature of this aspect, the base portion and the seal portionof the edge seal may be co-extruded.

In another feature of this aspect, the base portion and the seal portionmay be manufactured from different materials.

In another feature of this aspect, the base portion and the seal portionmay be manufactured from the same material.

In other features of this aspect, at least one of the one or morechannels of the base portion may include a plurality of panel retentionfingers for gripping the edge of the panel; and/or the panel retentionfingers may extend from sides of the at least one channel at aninwardly-oriented angle.

In other features of this aspect, the base portion may be manufacturedfrom a plastic material; and/or the seal portion may be manufacturedfrom a rubber material.

In another feature of this aspect, the plastic material may be an ABSplastic material.

In another feature of this aspect, the plastic material may be a PVCplastic material.

In another feature of this aspect, the base portion may include aplurality of channels, at least one of which is adapted to fittinglyaccommodate a separate rigid support structure coupled along the lengthof the edge seal.

Broadly defined, the present invention according to another aspect is amodular thermal isolation barrier for use in sealing gaps in a dataprocessing equipment structure. The modular thermal isolation barrierincludes an edge seal, a panel, and a rigid support structure. The edgeseal has a seal portion and a base portion with a plurality of channels.An edge of the panel is disposed within one of the plurality of channelsof the base portion of the edge seal such that the edge seal is seatedagainst the edge of the panel with the seal portion in position to abut,and establish a seal with, an adjacent structure. The rigid supportstructure has a generally uniform cross-sectional shape along its lengthand is coupled to the edge seal at another of the plurality of channels.

In a feature of this aspect, the seal portion may include a bulb-shapedseal for abutting, and establishing a seal with, the adjacent structure.

In other features of this aspect, the bulb-shaped seal may be bifurcatedat a distal end; the bulb-shaped seal may include convex and concaveportions at a distal end; and/or the bulb-shaped seal may include one ormore protrusions at a distal end.

In another feature of this aspect, the base portion and the seal portionof the edge seal may be co-extruded.

In another feature of this aspect, the base portion and the seal portionmay be manufactured from different materials.

In another feature of this aspect, the base portion and the seal portionmay be manufactured from the same material.

In other features of this aspect, at least one of the plurality ofchannels of the base portion may include a plurality of panel retentionfingers for gripping the edge of the panel; and/or the panel retentionfingers may extend from sides of the at least one channel at aninwardly-oriented angle.

In other features of this aspect, the base portion may be manufacturedfrom a plastic material; and/or the seal portion may be manufacturedfrom a rubber material.

In another feature of this aspect, the plastic material may be an ABSplastic material.

In another feature of this aspect, the plastic material may be a PVCplastic material.

In other features of this aspect, the rigid support structure mayinclude a pair of opposed retention flanges for coupling the rigidsupport structure to the edge seal; the rigid support structure mayinclude a plurality of channels extending along its length, at least oneof which is ridged to accommodate a threaded fastener; and/or the rigidsupport structure may be attachable to other support members of the dataprocessing equipment structure.

Broadly defined, the present invention according to another aspect is anextruded edge seal for a modular thermal isolation barrier. The extrudededge seal includes a base portion and a bulb-shaped seal portion. Thebase portion includes a plurality of channels, at least one of which isadapted to fittingly accommodate an edge of a panel. The bulb-shapedseal portion is attached to the base portion and adapted to abut, andestablish a seal with, an adjacent structure.

In features of this aspect, the bulb-shaped seal portion may bebifurcated at a distal end; the bulb-shaped seal portion may includeconvex and concave portions at a distal end; and/or the bulb-shaped sealportion includes one or more protrusions at a distal end.

In another feature of this aspect, the base portion and the bulb-shapedseal portion of the edge seal may be co-extruded.

In another feature of this aspect, the base portion and the bulb-shapedseal portion may be manufactured from different materials.

In another feature of this aspect, the base portion and the bulb-shapedseal portion may be manufactured from the same material.

In other features of this aspect, at least one of the plurality ofchannels of the base portion may include a plurality of panel retentionfingers for gripping the edge of the panel; and/or the panel retentionfingers may extend from sides of the at least one channel at aninwardly-oriented angle.

In other features of this aspect, the base portion may be manufacturedfrom a plastic material; and/or the bulb-shaped seal portion may bemanufactured from a rubber material.

In another feature of this aspect, the plastic material may be an ABSplastic material.

In another feature of this aspect, the plastic material may be a PVCplastic material.

In another feature of this aspect, at least one of the plurality ofchannels of the base portion may be adapted to fittingly accommodate aseparate rigid support structure coupled along the length of the baseportion.

Broadly defined, the present invention according to another aspect is adata processing equipment structure. The data processing equipmentstructure includes a plurality of vertical and horizontal framecomponents, which, together, define an equipment structure frame, aplurality of panels disposed relative to the equipment structure frameto define a periphery, an enclosure, and one or more modular thermalisolation barriers. A portion of the enclosure is located inside theperiphery and a portion of the enclosure is located outside theperiphery such that a gap exists between the enclosure and an adjacentone of the plurality of vertical and horizontal frame components of theequipment structure frame. Each of the one or more modular thermalisolation barriers includes a barrier panel and an edge seal, disposedrelative to the equipment structure frame such that the edge seal abuts,and establishes a seal with, the enclosure, thereby thermally sealingthe gap.

In a feature of this aspect, at least one of the plurality of verticaland horizontal frame components may be an extruded rigid supportstructure.

In another feature of this aspect, at least one of the plurality ofvertical and horizontal frame components may include an extruded rigidsupport structure coupled therewith.

In another feature of this aspect, the edge seal may include a sealportion and a base portion with one or more channels.

In another feature of this aspect, the seal portion may include abulb-shaped seal for abutting, and establishing a seal with, theenclosure.

In other features of this aspect, the bulb-shaped seal may be bifurcatedat a distal end; the bulb-shaped seal may include convex and concaveportions at a distal end; and/or the bulb-shaped seal may include one ormore protrusions at a distal end.

In another feature of this aspect, the base portion and the seal portionof the edge seal may be co-extruded.

In other features of this aspect, at least one of the one or morechannels of the base portion may include a plurality of panel retentionfingers for gripping the edge of the barrier panel; and/or the panelretention fingers may extend from sides of the at least one channel atan inwardly-oriented angle.

Broadly defined, the present invention according to another aspect is adata processing equipment structure. The data processing equipmentstructure includes a plurality of vertical and horizontal framecomponents, which, together, define an equipment structure frame. Thedata processing equipment structure further includes a pair of modularthermal isolation barriers disposed relative to the equipment structureframe, each having a panel and an edge seal. The modular isolationbarriers are deployed against each other such that the respective edgeseals abut, and establish a seal with, each other, thereby defining acontinuous wall structure of the equipment structure frame.

In a feature of this aspect, each edge seal may include a seal portionand a base portion with one or more channels.

In another feature of this aspect, the seal portion of each edge sealmay include a bulb-shaped seal.

In other features of this aspect, the bulb-shaped seal of each edge sealmay be bifurcated at a distal end; the bulb-shaped seal of each edgeseal may include convex and concave portions at a distal end; and/or thebulb-shaped seal of each edge seal may include a plurality ofprotrusions at a distal end.

In another feature of this aspect, when the edge seals of the pair ofmodular thermal isolation barriers are deployed against each other, thebifurcated distal ends of the edge seals may abut and deflect eachother, thereby sealing a gap between the pair of modular thermalisolation barriers.

In another feature of this aspect, when the edge seals of the pair ofmodular thermal isolation barriers are deployed against each other, thebifurcated distal end of one of the edge seals may envelop and nestaround the bifurcated distal end of the other edge seal, thereby sealinga gap between the pair of modular thermal isolation barriers.

In another feature of this aspect, when the edge seals of the pair ofmodular thermal isolation barriers are deployed against each other, theconvex and concave portions of the edge seals may abut and matingly fitagainst each other, thereby sealing a gap between the pair of modularthermal isolation barriers.

In another feature of this aspect, when the edge seals of the pair ofmodular thermal isolation barriers are deployed against each other, oneof the plurality of protrusions of one of the edge seals may fit betweena pair of adjacent protrusions of the other edge seal, thereby sealing agap between the pair of modular thermal isolation barriers.

In another feature of this aspect, the base portion and the seal portionof each edge seal may be co-extruded.

In other features of this aspect, at least one of the one or morechannels of the base portion of each edge seal may include a pluralityof panel retention fingers for gripping the edge of the correspondingpanel; and/or the panel retention fingers of each edge seal may extendfrom sides of the at least one channel at an inwardly-oriented angle.

Broadly defined, the present invention according to another aspect is adata processing equipment structure. The data processing equipmentstructure includes a plurality of vertical and horizontal framecomponents, which, together, define an equipment structure frame. Thedata processing equipment structure further includes a plurality ofpanels disposed relative to the equipment structure frame to define aperiphery. At least one of the plurality of vertical and horizontalframe components is an extruded strut having a generally uniformcross-section. The extruded strut includes an outwardly-facing channelextending along each of a pair of opposing sides of the extruded strut,at least one of which includes a set of evenly-spaced ridges, extendingalong each of two sides of the channel, for accommodating a threadedfastener. The extruded strut further includes one or more ledges, eachhaving a depth sufficient to accommodate the thickness of one of theplurality of panels.

In features of this aspect, the extruded strut may be a vertical framecomponent; the extruded strut may be a horizontal frame component; eachof at least one of the vertical frame components and at least one of thehorizontal frame components may be an extruded strut having identicaldimensions with each other; and/or the outwardly-facing channels on eachpair of opposing sides of the extruded strut may be aligned with eachother.

Broadly defined, the present invention according to another aspect is adata processing equipment structure. The data processing equipmentstructure includes a plurality of vertical and horizontal framecomponents, which, together, define an equipment structure frame. Thedata processing equipment structure further includes a plurality ofpanels disposed relative to the equipment structure frame to define aperiphery and at least one gusset connecting at least one of thevertical frame components with at least one of the horizontal framecomponents. The gusset includes a generally triangular body and a pairof mounting plates. Each mounting plate extends generallyperpendicularly from one of the edges of the generally triangular bodyand each includes a mounting aperture and at least one positioning tab.Each mounting tab accommodates a fastener such that one of the pair ofmounting plates is mounted to the at least one vertical frame componentand the other of the pair of mounting plates is mounted to thehorizontal frame component. The at least one positioning tab of one ofthe pair of mounting plates extends into a corresponding channel of theat least one vertical frame component and the at least one positioningtab of the other of the pair of mounting plates extends into acorresponding channel of the at least one horizontal frame component.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features, embodiments, and advantages of the present inventionwill become apparent from the following detailed description withreference to the drawings, wherein:

FIG. 1 is an isometric view of a data processing equipment structure foruse with modular thermal isolation barriers to segregate heated air fromcooled air in accordance with one or more preferred embodiments of thepresent invention;

FIG. 2 is an isometric view of the data processing equipment structureof FIG. 1, illustrating the use of two modular thermal isolationbarriers to accommodate an awkwardly located equipment enclosure;

FIG. 3 is a fragmentary isometric view of an upper end of the edge sealof one of the modular thermal isolation barriers of FIG. 2;

FIG. 4 is a top or top cross-sectional view of the edge seal of FIG. 3;

FIG. 5 is a fragmentary top or top cross-sectional view of a modularthermal isolation barrier, using the edge seal of FIG. 4, shown deployedagainst the right side of the equipment enclosure of FIG. 2;

FIG. 6 is a fragmentary isometric view of an upper end of a rigidsupport structure adapted to be coupled to the edge seal of FIG. 3;

FIG. 7 is a fragmentary top or top cross-sectional view of a modularthermal isolation barrier, using the edge seal of FIG. 4 coupled to therigid support structure of FIG. 6, shown deployed against the right sideof the equipment enclosure of FIG. 2;

FIG. 8 is an isometric view of the data processing equipment structureof FIG. 1, illustrating the use of two modular thermal isolationbarriers abutting each other to create a continuous wall structure;

FIG. 9 is a fragmentary top or top cross-sectional view of two modularthermal isolation barriers, each using the edge seal of FIG. 4, showndeployed against each other in the manner shown in FIG. 8;

FIG. 10 is a fragmentary top or top cross-sectional view of two modularthermal isolation barriers, each using the edge seal of FIG. 4, showndeployed against each other in an alternative arrangement;

FIG. 11 is a fragmentary top or cross-sectional view of two alternativemodular thermal isolation barriers, each using an alternative edge seal,shown deployed against each other;

FIG. 12 is a fragmentary top or cross-sectional view of two alternativemodular thermal isolation barriers, each using another alternative edgeseal, shown deployed against each other;

FIG. 13 is an isometric view of one of the panels of FIG. 1;

FIG. 14 is an isometric view of one of the horizontal struts of the dataprocessing equipment structure of FIG. 1;

FIG. 15 is an end view of the strut of FIG. 14, illustrating thecross-section thereof;

FIG. 16 is an isometric view of one of the gussets of FIG. 1;

FIG. 17 is an enlarged, partially exploded, fragmentary view of one ofthe joints of the structure of FIG. 1; and

FIG. 18 is an end view of the strut of FIG. 15, illustrating a splicebracket installed therein.

DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one havingordinary skill in the relevant art (“Ordinary Artisan”) that the presentinvention has broad utility and application. Furthermore, any embodimentdiscussed and identified as being “preferred” is considered to be partof a best mode contemplated for carrying out the present invention.Other embodiments also may be discussed for additional illustrativepurposes in providing a full and enabling disclosure of the presentinvention. Moreover, many embodiments, such as adaptations, variations,modifications, and equivalent arrangements, will be implicitly disclosedby the embodiments described herein and fall within the scope of thepresent invention.

Accordingly, while the present invention is described herein in detailin relation to one or more embodiments, it is to be understood that thisdisclosure is illustrative and exemplary of the present invention, andis made merely for the purposes of providing a full and enablingdisclosure of the present invention. The detailed disclosure herein ofone or more embodiments is not intended, nor is to be construed, tolimit the scope of patent protection afforded the present invention,which scope is to be defined by the claims and the equivalents thereof.It is not intended that the scope of patent protection afforded thepresent invention be defined by reading into any claim a limitationfound herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps ofvarious processes or methods that are described herein are illustrativeand not restrictive. Accordingly, it should be understood that, althoughsteps of various processes or methods may be shown and described asbeing in a sequence or temporal order, the steps of any such processesor methods are not limited to being carried out in any particularsequence or order, absent an indication otherwise. Indeed, the steps insuch processes or methods generally may be carried out in variousdifferent sequences and orders while still falling within the scope ofthe present invention. Accordingly, it is intended that the scope ofpatent protection afforded the present invention is to be defined by theappended claims rather than the description set forth herein.

Additionally, it is important to note that each term used herein refersto that which the Ordinary Artisan would understand such term to meanbased on the contextual use of such term herein. To the extent that themeaning of a term used herein—as understood by the Ordinary Artisanbased on the contextual use of such term—differs in any way from anyparticular dictionary definition of such term, it is intended that themeaning of the term as understood by the Ordinary Artisan shouldprevail.

Furthermore, it is important to note that, as used herein, “a” and “an”each generally denotes “at least one,” but does not exclude a pluralityunless the contextual use dictates otherwise. Thus, reference to “apicnic basket having an apple” describes “a picnic basket having atleast one apple” as well as “a picnic basket having apples.” Incontrast, reference to “a picnic basket having a single apple” describes“a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one ofthe items,” but does not exclude a plurality of items of the list. Thus,reference to “a picnic basket having cheese or crackers” describes “apicnic basket having cheese without crackers,” “a picnic basket havingcrackers without cheese,” and “a picnic basket having both cheese andcrackers.” Finally, when used herein to join a list of items, “and”denotes “all of the items of the list.” Thus, reference to “a picnicbasket having cheese and crackers” describes “a picnic basket havingcheese, wherein the picnic basket further has crackers,” as well asdescribes “a picnic basket having crackers, wherein the picnic basketfurther has cheese.”

Referring now to the drawings, in which like numerals represent likecomponents throughout the several views, the preferred embodiments ofthe present invention are next described. The following description ofone or more preferred embodiment(s) is merely exemplary in nature and isin no way intended to limit the invention, its application, or uses.

FIG. 1 is an isometric view of a data processing equipment structure 10for use with modular thermal isolation barriers to segregate heated airfrom cooled air in accordance with one or more preferred embodiments ofthe present invention. As shown in FIG. 1, the data processing equipmentstructure 10 includes vertical struts 12, horizontal struts 14, andpanels 18. The vertical and horizontal struts 12,14 are arranged into aframework formed from a plurality of interconnected rectangular frames.Some of the rectangular frames are oriented vertically to form the wallsof the structure 10, while others of the frames are orientedhorizontally to form the ceiling or floor of the structure 10. FIG. 13is an isometric view of one of the panels 18 of FIG. 1. In at least someembodiments, the panels 18 are supported by these rectangular frames,particularly including the vertical wall frames and the horizontalceiling frames. In some of these embodiments, each panel 18 isrectangular and is supported on each of its four sides by a vertical orhorizontal strut 12,14.

As used herein, the term “data processing equipment” refers to a widerange of electronic equipment as well as racks, frames, enclosures, andthe like that are typically used to house such equipment. Structuressuch as the structure 10 of FIG. 1 house a wide variety of electronicequipment, including storage equipment, servers, switches and other likedevices and equipment for data processing. The panels 18 tend to preventheated air inside the structure 10 from escaping and mixing with coolair outside the structure 10 (or vice versa), or conversely to preventheated air outside the structure 10 from entering the interior of thestructure 10 and mixing with the cool air therein (or vice versa).

Although in at least some embodiments, data processing equipmentstructures other than that of FIG. 1 may be utilized, the structure 10of FIG. 1 has several features, aspects, and other innovations of itsown. In the data processing equipment structure 10 of FIG. 1, thevertical and horizontal struts 12,14 are each of extruded constructionand may utilize an identical cross-section. In this regard, FIG. 14 isan isometric view of one of the horizontal struts 14 of the dataprocessing equipment structure 10 of FIG. 1. In fact, the vertical andhorizontal struts 12,14 may also, in some embodiments, be of identicallengths, and thus may be identical to each other. Thus, in suchembodiments, the horizontal strut 14 of FIG. 14 may also be utilized asa vertical strut 12.

FIG. 15 is an end view of the strut 14 of FIG. 14, illustrating thecross-section thereof. As shown therein, the strut 14 includes anoutwardly-facing channel 108 running along each of its four sides. In atleast some embodiments, including the one illustrated, the channels 108on each pair of opposing sides are aligned with each other, but in someembodiments the channels are not aligned with each other. In at leastsome embodiments, the channels 108 are all of the same width andconstruction. Viewed in cross-section, each channel 108 includes a baseand two sides, and a set of evenly-spaced ridges extends along each ofthe two sides. In at least some embodiments, the ridges on one side ofthe channel 108 are offset from the ridges on the opposite side of thechannel 108. More particularly, in at least some embodiments, the ridgeson one side of the channel 108 are offset from the ridges on theopposite side of the channel 108 by a distance equal to approximatelyone-half the width of one of the ridges. Such ridges are believed to beparticularly useful in receiving and retaining a threaded fastener 103inserted perpendicularly into the channel 108 when the fastener 103utilizes threads whose depth and spacing is similar to the depth andspacing of the ridges in the channel 108.

In at least some embodiments, the struts 12,14 may be connected togetherusing gussets 16. In this regard, FIG. 16 is an isometric view of one ofthe gussets 16 of FIG. 1. As shown therein, the gusset 16 is triangularand includes two mounting plates 101, each of which includes a mountingaperture 102 and a pair of positioning tabs or other protrusions 104.The diameter of the mounting aperture 102 is preferably selected tomatch the width of at least one of the channels 108 in the struts 12,14,and the width of the positioning tabs 104 is selected to fit relativelysnugly within the same channel 108. Thus, the gusset 16 may be connectedto a strut 12,14 by inserting the positioning tabs 104 of one mountingplate 101 into one of the channels 108 in the strut 12,14, inserting afastener 103 (shown in FIG. 17) through the mounting aperture 102 andinto the same channel 108, and screwing (rotating) the fastener 103 intothe ridges until the gusset 16 is tight against the strut 12,14. Thegusset 16 may be connected to a second strut 12,14 that is perpendicularto the first strut 12,14 by repeating the process using the tabs 104 andaperture 102 of the other mounting plate 101. In this way, twointersecting (perpendicular) struts may be connected together. Morecomplicated joints or intersections in a data processing equipmentstructure 10 may be assembled using multiple gussets 16. In anyparticular strut 12,14, one, two, three, or all four of the channels 108may be utilized. In this regard, FIG. 17 is an enlarged, partiallyexploded, fragmentary view of one of the joints of the structure 10 ofFIG. 1. As shown therein, five gussets 16 have been utilized to connectthree horizontal struts 14 and one vertical strut 12 together in themanner described above.

Referring again to FIG. 15, the strut 14 further includes one or moreledges 107. Each ledge 107 has a depth suitable for receiving one of thepanels 18. The panels 18 may be mounted on or with these ledges 107 asshown in FIG. 17. Notably, in FIG. 17, the panels 18 are shown as beingtransparent, with objects behind them shown in broken lines.

Referring again to FIG. 15, the strut 14 further includes additionalchannels or slots 105 for receiving a splice bracket 109. In thisregard, FIG. 18 is an end view of the strut 14 of FIG. 15, illustratinga splice bracket 109 installed therein. A splice bracket 109 may be usedto attach two struts 14 end-to-end, as shown in FIG. 1. The splicebracket 109 includes two ear flanges 110 that are sized and proportionedto fit within the channels or slots 105 on each strut 14. By insertingone end of the splice bracket 109 in the end of a first strut 14 and theother end of the splice bracket 109 in the end of a second strut 14, thetwo struts 14 may be coupled together. The arrangement may be fixed inplace by inserting threaded fasteners 103 through apertures in thesplice bracket 109 and screwing (rotating) the fasteners 103 into aridged channel 108 in the struts 14 until the splice bracket 109 istight against the struts 14. Several such arrangements are shown in FIG.1.

Although in practice, many data processing equipment structures may beconstructed in convenient shapes with no unusual obstacles or otherincongruous geometry problems, such situations do occur. For example,FIG. 2 is an isometric view of the data processing equipment structure10 of FIG. 1, illustrating the use of two modular thermal isolationbarriers 24 to accommodate an awkwardly located equipment enclosure 22.In particular, the enclosure extends through a wall of the structure 10,with portions of the enclosure 22 being located both inside and outsidethe periphery of the structure 10. Although from a design perspective,it would be preferable to avoid such a situation, the modular thermalisolation barriers 24 make it possible to accommodate the unusualgeometry and to maintain the heated air/cooled air segregation of thedata processing equipment structure 10.

Each modular thermal isolation barrier 24 includes a panel 28 and atleast one edge seal 26. FIG. 3 is a fragmentary isometric view of anupper end of the edge seal 26 of one of the modular thermal isolationbarriers 24 of FIG. 2, and FIG. 4 is a top or top cross-sectional viewof the edge seal 26 of FIG. 3. As shown therein, the edge seal 26 is anextruded member having a generally uniform cross-section along itslength. In at least some embodiments, it is manufactured from materialwhich may be cut relatively easily to make pieces of different lengths.

As perhaps best shown in FIG. 4, the cross-section of the edge seal 26includes a multi-channel base portion 68, a “bulb”-type seal portion 67,and a plurality of panel retention fingers 64 within one of the channels62 on the base portion 68. In at least some embodiments, the bulb sealportion 67 is bifurcated at a distal end, resulting in a “C” shape, fora purpose described hereinbelow, but in other embodiments, the bulb sealmay be a fully closed structure (i.e., an “O” shape). Other geometriesare likewise possible. In some embodiments, the bulb seal portion 67 andthe multi-channel base portion 68 are manufactured from the samematerial in a single extrusion process. In other embodiments, the bulbseal portion 67 and the multi-channel base portion 68 are manufacturedfrom different materials in a co-extrusion process. In still otherembodiments, bulb seal portion 67 and the multi-channel base portion 68are manufactured from different materials in separate extrusionprocesses, and then are attached together. Likewise, the panel retentionfingers 64 may be made of the same material as the base portion 68, orof a different material. In some of the latter embodiments, theretention fingers 64, base portion 68, and bulb seal portion 67 are allmade of different materials. In some embodiments, the base portion 68 ismade from ABS or PVC plastic (or some other rigid plastic), theretention fingers 64 are made from flexible rubber such as flexiblealcryn, and the bulb seal portion 67 is made of a material similar tothat of the flexible fingers 64, or from a softer rubber or foam rubber.The base portion 68 could also be made out of at least some metals, suchas aluminum.

As perhaps best understood from FIG. 4, the base portion 68 includes aplurality of channels 62,66. In particular, an end channel 62 is sizedto receive a panel 28, and two side channels 66 are provided forcoupling to a rigid support structure (described hereinbelow). Theretention fingers 64 extend at an inwardly-oriented angle from sides ofthe end channel 62 to help retain an edge of the panel 28, as describedbelow.

FIG. 5 is a fragmentary top or top cross-sectional view of a modularthermal isolation barrier 24, using the edge seal 26 of FIG. 4, showndeployed against the right side of the equipment enclosure 22 of FIG. 2.As shown therein, the panel 28 is inserted into the end channel 62. Thisinsertion is opposed by the retention fingers 64, but the fingers 64flex enough, in the direction of insertion, to accommodate the edge ofthe panel 28. However, once the panel 28 is fully seated within thechannel 62, the same retention fingers 64 tend to prevent the panel 28from being removed. This is accomplished by the compression that isintroduced by the panel 28 against the fingers 64, and the angleddirection of the fingers 64.

When the modular thermal isolation barrier 24 is deployed as shown inFIG. 5, the panel 28 blocks most of the air that could otherwise pass bythe side of the equipment enclosure 22 and either into or out of theinterior of the data processing equipment structure 10. The gap betweenthe edge of the panel 28 and the side of the enclosure 22 is filled andsealed by the edge seal 26, the bulb seal portion 67 of which iscompressed against the enclosure 22.

Notably, the use of the modular thermal isolation barriers 24, as shownin FIG. 2, allows the original panel 18 to be omitted and the resultinggap filled with smaller panels 28. Such a solution is not possible withthe original panels 18 by themselves because they are not typicallysized to fit non-standard openings. In addition, they are not typicallymountable in non-standard locations. The modular thermal isolationbarrier 24 thus offers considerable convenience and flexibility to theinstaller or designer.

In the latter regard, it is often desirable to provide additionalsupport to the modular thermal isolation barriers 24, either as primarysupport or as secondary support to maintain them in place. FIG. 6 is afragmentary isometric view of an upper end of a rigid support structure70 adapted to be coupled to the edge seal 26 of FIG. 3, and FIG. 7 is afragmentary top or top cross-sectional view of a modular thermalisolation barrier 24, using the edge seal 26 of FIG. 4 coupled to therigid support structure 70 of FIG. 6, shown deployed against the rightside of the equipment enclosure 22 of FIG. 2. Like the edge seal 26, therigid support structure 70 may also be an extruded member having agenerally uniform cross-section along its length. In at least someembodiments, it is manufactured from material which may be cutrelatively easily to make pieces of different lengths. In onecontemplated embodiment, the rigid support structure 70 is made out ofaluminum. In another contemplated embodiment, the rigid supportstructure 70 is made out of a plastic material.

The rigid support structure 70 includes six channels 72,74,76 and a pairof opposed retention flanges 78 for coupling the structure 70 to theedge seal 26, as shown in FIG. 7. The channels include a pair of opposedridged channels 76 in the sides of the structure 70, a pair of opposedridged channels 72 in the ends of the structure 70, and a pair ofopposed supplemental channels 74 in the ends of the structure 70,adjacent the ridged channels 72. Each of the ridged channels 72,76 isadapted to receive a threaded fastener (not shown) inserted into it, andbecause the channels 72,76 extend the length of the structure 70,fasteners may be utilized at an infinite number of locations along suchlength.

The rigid support structure 70 may itself be attached to other supportmembers of the data processing equipment structure 10, such as thevertical struts 12 and horizontal struts 14. Alternatively oradditionally, a data processing equipment structure 10 may be assembledusing multiple rigid support structures 70, alone or in combination withthe vertical struts 12 and horizontal struts 14. The edge seals 26 maybe coupled to the rigid support structures 70, and thus the panels 28may be supported.

In this regard, the modular thermal isolation barriers 24 may beutilized in other ways as well. FIG. 8 is an isometric view of the dataprocessing equipment structure 10 of FIG. 1, illustrating the use of twomodular thermal isolation barriers 24 abutting each other to create acontinuous wall structure. FIG. 9 is a fragmentary top or topcross-sectional view of two modular thermal isolation barriers 24, eachusing the edge seal 26 of FIG. 4, shown deployed against each other inthe manner shown in FIG. 8. As shown therein, each barrier 24 includes apanel 28 and an edge seal 26, with the respective edge seals 26 abuttingeach other in opposed fashion, so as to seal the gap between adjacentpanels 28. In this manner, an entire wall may be created from modularthermal isolation barriers 24.

The edge seals 26 provide an additional sealing feature as well. Inparticular, FIG. 10 is a fragmentary top or top cross-sectional view oftwo modular thermal isolation barriers 24, each using the edge seal 26of FIG. 4, shown deployed against each other in an alternativearrangement. As shown in FIG. 10, the bulb seal portion 83 of one edgeseal 26 has been inserted through the bifurcated opening of the bulbseal portion 82 of the other edge seal 26. The outer bulb seal portion82 may be forced open wider than normal, and the inner bulb seal portion83 may be compressed somewhat, but the flexible nature of the bulb sealportions 82,83 facilitates this. The resulting “nested” arrangementeliminates nearly all air gaps between adjacent panels 28 andeffectively fastens the edge seals 26 together.

In at least some embodiments of the present invention, other edge sealgeometries are also possible. In this regard, FIG. 11 is a fragmentarytop or cross-sectional view of two alternative modular thermal isolationbarriers 124, each using an alternative edge seal 126, shown deployedagainst each other. Each edge seal 126 includes a shaped seal portion167, the geometry of which facilitates the edge seals 126 being deployedagainst each other in such a way that the gap between adjacent panels iseffectively sealed. Each shaped seal portion 167 of the edge seals 126includes convex and concave portions 169,171 that can be matingly pairedagainst one another to seal the gap between adjacent panels.

Similarly, FIG. 12 is a fragmentary top or cross-sectional view of twoalternative modular thermal isolation barriers 224, each using anotheralternative edge seal 226, shown deployed against each other. Each edgeseal 226 includes a shaped seal portion 267, the geometry of whichfacilitates the edge seals 226 being deployed against each other in sucha way that the gap between adjacent panels is effectively sealed. Eachshaped seal portion 267 of the edge seals 226 includes a plurality ofprotrusions 269. When deployed against each other, a protrusion 269 onone of the edge seals 226 is positionable between two protrusions 269 onthe other edge seal 226, thereby sealing the gap between adjacentpanels.

Among other advantages, the present invention provides a barrier againstthermal communication between separate air spaces. The invention allowsthe user to build a structure that may seal one or more walls/planes ofan air space around uneven geometry and objects that are placed inbetween the sealing plane/s. The invention also allows the user toquickly alter the shape of the sealing plane to seal around additionalopenings or obstructions with minimal disassembly. This structure alsohas the ability to add stiffeners as needed for more structure andadditional mounting points.

Based on the foregoing information, it will be readily understood bythose persons skilled in the art that the present invention issusceptible of broad utility and application. Many embodiments andadaptations of the present invention other than those specificallydescribed herein, as well as many variations, modifications, andequivalent arrangements, will be apparent from or reasonably suggestedby the present invention and the foregoing descriptions thereof, withoutdeparting from the substance or scope of the present invention.

Accordingly, while the present invention has been described herein indetail in relation to one or more preferred embodiments, it is to beunderstood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for the purpose of providing afull and enabling disclosure of the invention. The foregoing disclosureis not intended to be construed to limit the present invention orotherwise exclude any such other embodiments, adaptations, variations,modifications or equivalent arrangements; the present invention beinglimited only by the claims appended hereto and the equivalents thereof.

What is claimed is:
 1. A data processing equipment arrangementcomprising: a frame structure formed of a plurality of interconnectedvertical and horizontal struts and defining a plurality of openings,each of which is adapted to receive one or more panels for substantiallyenclosing the frame structure; at least one equipment structure arrangedto pass through a selected one of the plurality of openings, wherein agap is formed between a side of the at least one equipment structure andthe frame structure; and a modular thermal isolation barrier having agenerally uniform cross-sectional shape along its length and includingan edge seal having a seal portion and a base portion, the base portionincluding a panel-receiving end channel and at least one side channel,and a barrier panel, an edge of which is disposed within thepanel-receiving end channel; wherein the modular thermal isolationbarrier is arranged such that the barrier panel generally fills the gapand the seal portion is in abutment with, and is deflected by, the sideof the equipment structure, thereby preventing passage of air throughthe gap.
 2. The data processing equipment arrangement of claim 1,wherein the seal portion and the base portion are formed of differentmaterials
 3. The data processing equipment arrangement of claim 1,wherein the seal portion and the base portion are formed of the samematerial.
 4. The data processing equipment arrangement of claim 1,wherein the seal portion is bifurcated at a distal end.
 5. The dataprocessing equipment arrangement of claim 1, wherein the seal portionincludes convex and concave portions at a distal end.
 6. The dataprocessing equipment arrangement of claim 1, wherein the seal portionincludes one or more protrusions at a distal end.
 7. The data processingequipment arrangement of claim 1, further comprising a rigid supportstructure received within the at least one side channel, the rigidsupport structure having a generally uniform cross-sectional shape alongits length.
 8. The data processing equipment arrangement of claim 7,wherein the rigid support structure includes a plurality of channels,extending along the length thereof, for coupling the rigid supportstructure to one or more other structures.
 9. The data processingequipment arrangement of claim 8, wherein at least one of the pluralityof channels of the rigid support structure is ridged to accommodate athreaded fastener.
 10. The data processing equipment arrangement ofclaim 7, wherein the rigid support structure includes a pair of opposedretention flanges for coupling the rigid support structure to the edgeseal.
 11. A data processing equipment arrangement comprising: a framestructure formed of a plurality of interconnected vertical andhorizontal struts and defining a plurality of openings, each of which isadapted to receive one or more panels for substantially enclosing theframe structure; at least one equipment structure arranged to passthrough a selected one of the plurality of openings, wherein a gap isformed between a side of the at least one equipment structure and theframe structure; and a modular thermal isolation barrier having agenerally uniform cross-sectional shape along its length and includingan edge seal having a seal portion and a base portion each formed ofdifferent materials, the base portion including a panel-receiving endchannel and a pair of opposed side channels, and a barrier panel, anedge of which is disposed within the panel-receiving end channel;wherein the modular thermal isolation barrier is arranged such that thebarrier panel generally fills the gap and the seal portion is inabutment with, and is deflected by, the side of the equipment structure,thereby preventing passage of air through the gap.
 12. The dataprocessing equipment arrangement of claim 11, wherein the seal portionis bifurcated at a distal end.
 13. The data processing equipmentarrangement of claim 11, wherein the seal portion includes convex andconcave portions at a distal end.
 14. The data processing equipmentarrangement of claim 11, wherein the seal portion includes one or moreprotrusions at a distal end.
 15. The data processing equipmentarrangement of claim 11, further comprising at least one rigid supportstructure received within one of the pair of side channels, the rigidsupport structure having a generally uniform cross-sectional shape alongits length.
 16. The data processing equipment arrangement of claim 15,wherein the rigid support structure includes a plurality of channels,extending along the length thereof, for coupling the rigid supportstructure to one or more other structures.
 17. The data processingequipment arrangement of claim 16, wherein at least one of the pluralityof channels of the rigid support structure is ridged to accommodate athreaded fastener.
 18. The data processing equipment arrangement ofclaim 15, wherein the rigid support structure includes a pair of opposedretention flanges for coupling the rigid support structure to the edgeseal.
 19. An edge seal for a modular thermal isolation barrier forpreventing passage of air through a gap in a data processing equipmentarrangement, the edge seal comprising: a seal portion formed of aresilient material capable of deflection by a rigid adjacent structure;and a base portion formed of a rigid material, the base portionincluding a pair of side channels opening at opposite sides thereof anda panel-receiving end channel, the panel-receiving end channel includinga plurality of inwardly-oriented retention fingers for retaining an edgeof a panel; wherein each of the seal portion and the base portion has agenerally uniform cross-sectional shape; and wherein the base portion isadapted to accommodate a rigid support structure received within one ofthe pair of side channels.
 20. The edge seal of claim 19, wherein theseal portion is bifurcated at a distal end.